Machining Centers

General Manufacturing Processes Engr.-20.2710 Instructor - Sam Chiappone

History

1947 - John Parsons and US Air Force define a need to develop a machine tool capable of machining complex and close tolerance aircraft parts with the same quality time after time (repeatability). 1949 - MIT is the subcontractor and builds the machine for the project.

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History: Continued

1959 - MIT announces Automatic Programmed Tools (APT) programming language 1960 - Direct Numerical Control (DNC). This eliminates paper tape punch programs and allows programmers to send files directly to machine tools

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History: Continued

1968 - Kearney & Trecker machine tool builders market first machining center 1970s - CNC machine tools & Distributed Numerical Control 1980s - Graphics based CAM systems introduced. Unix and PC based systems available

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History: Continued

1990s - Price drop in CNC technology 1997 - PC- Windows/NT based Open Modular Architecture Control (OMAC) systems introduced to replace firmware controllers.

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Control Systems

Open-Loop Control
Stepper motor system Current pulses sent from control unit to motor Each pulse results in a finite amount of revolution of the motor001 is possible

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Control Systems

Open-Loop Limitations
Control unit assumes desired position is achieved No positioning compensation Typically, a lower torque motor

Open-Loop Advantages
Less complex, Less costly, and lower maintenance costs

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Control Systems

Closed-Loop Control
Variable DC motors - Servos Positioning sensors -Resolvers
Feedback to control unit Position information compared to target location Location errors corrected

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Control Systems

Closed-Loop Advantages
DC motors have the ability to reverse instantly to adjust for position error Error compensation allows for greater positional accuracy (.0001) DC motors have higher torque ranges vs.. stepper motors

Closed-loop limitations
Cost
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Three Basic Categories of Motion Systems

Point to Point - No contouring capability Straight cut control - one axis motion at a time is controlled for machining Contouring - multiple axiss controlled simultaneously

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Three Basic Categories of Motion Systems

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CNC vs. NC Machine Tools

Computer Numerical Control (CNC) - A numerical control system in which the data handling, control sequences, and response to input is determined by an on-board computer system at the machine tool.

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CNC

Advantages
Increased Program storage capability at the machine tool Program editing at the machine tool Control systems upgrades possible Option -resident CAM system at machine tool Tool path verification

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NC

Numerical Control (NC) - A control system which primarily processes numeric input. Limited programming capability at the machine tool. Limited logic beyond direct input. These types of systems are referred to as hardwire controls and were popular from the 1950s to 1970s.

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Machining Centers

A machining center can be defined as a machine tool capable of:

Multiple operation and processes in a single set-up utilizing multiple axis Typically has an automatic mechanism to change tools

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Machining Centers
Machine motion is programmable Servo motors drive feed mechanisms for tool axiss Positioning feedback is provided by resolvers to the control system

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Machining Centers

Example - A turning center capable of OD turning, external treading, cross-hole drilling, engraving, and milling. All in machining is accomplished in one set-up. Machine may have multiple spindles.

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Machining Centers

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Programming Methods

Automatically Programmed Tools (APT)

A text based system in which a programmer defines a series of lines, arcs, and points which define the overall part geometry locations. These features are then used to generate a cutter location (CL) file.

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Programming Methods-APT
Developed as a joint effort between the aerospace industry, MIT, and the US Airforce Still used today and accounts for about 5 -10% of all programming in the defense and aerospace industries

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Programming Methods-APT
Requires excellent 3D visualization skills Capable of generating machine code for complicated part programs
5 axis machine tools

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Programming Methods-APT

Part definition

P1=Point/12,20,0 C1=Circle/Center,P1,Radius,3 LN1=Line/C1. ATANGL,90

Cutter Commands

TLRT,GORT/LN1.TANTO,C1 GOFWD/C1,TANTO,L5

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Programming Methods-CAM

Computer Aided Machining (CAM) Systems

Graphic representation of the part PC based Integrated CAD/CAM functionality Some built-in expertise

Speed & feed data based on material and tool specifications

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Programming Methods-CAM
Tool & material libraries Tool path simulation Tool path editing Tool path optimization Cut time calculations for cost estimating

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Programming Methods-CAM
Import / export capabilities to other systems
Examples: Drawing Exchange Format (DXF) Initial Graphics Exchange Standard (IGES)

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Traditional CAD to NC File Process

Start with graphic representation of part

Direct input Import from external system
Example DXF / IGES

2D or 3D scan
Model or Blueprint

(At this point you have a graphics file of your geometry)

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Traditional CAD to NC File Process

Define cutter path by selecting geometry

Contours Pockets Hole patterns Surfaces Volume to be removed (At this point the system knows what you want to cut)

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Traditional CAD to NC File Process

Define cut parameters

Tool information
Type, Rpm, Feed

Cut method
Example - Pocket mill zig-zag, spiral, inside-out Rough and finish parameters

(At this point the system knows how you want to cut the part)

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Traditional CAD to NC File Process

Execute cutter simulation

Visual representation of cutter motion

Modify / delete cutter sequences

(At this point the system has a generic cutter location (CL) file of the cut paths)

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Traditional CAD to NC File Process

Post Processing
CL file to machine specific NC code

Filters CL information and formats it into NC code based on machine specific parameters
Work envelope Limits - feed rates, tool changer, rpms, etc. G & M function capabilities

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Output - NC Code

Numerical Control (NC) Language

A series of commands which direct the cutter motion and support systems of the machine tool.

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Output: NC Code

G-Codes (G00, G1, G02, G81) Coordinate data (X,Y,Z) Feed Function (F) Miscellaneous functions (M13) N - Program sequence number T - Tool call S - Spindle command

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Output: NC Code

NC Program Example
N01G90 G80 N03 GOO T12 M06 N05 GOO X0 Y0 Z.1 F10 S2500 M13 N07 G1Z-.5 N09 G02 X-10. I0J0F20 N13 X0Y10 N17 X10Y0 N19 X0Y-10 N21 X-10Y0 N23 M2

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Output: NC Code - Canned Cycles

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Traditional CAD to NC File Process

Import File DXF IGES Geometry Direct input

Post Process

CL File

Tool Path Generation What you want to cut How you want to cut Tool Type Rpms Feeds Method Canned cycles Cut direction

NC Code N1 G80 G90 N3 G0 T01 M06 N5 G0 X0 Y0

OEM Custom Language

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New Models

Feature Based CAD/CAM Systems Standard for the Exchange of Product Model Data (STEP) Compliant Controllers
Geometric data exchange between systems including CAM http://www.steptools.com/

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Advantages of CNC Machine Tools

Ease of part duplication Flexibility Repeatability Quality control through process control

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Advantages of CNC Machine Tools

Accommodates simple to complex parts geometry Improved part aesthetics Increased productivity Technology costs are decreasing

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Advantages of CNC Machine Tools

Reduced set-up time Reduced lead times Reduced inventory Better machine utilization Job advancement opportunities

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Advantages of CNC Machine Tools

CNC machine tools are more rigid than conventional machine tools
$$$- Climb milling requires about 10 - 15 % less horsepower vs. conventional cutting, but requires a ridged machine tool with no backlash Increased Rpms and feeds

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